®®
EngineEngine Model Cat ® 3508B EUIGross Power – 746 kW 1,000 hpSAE J1995Flywheel Power 699 kW 938 hp
Operating SpecificationsNominal Payload 90.4 tonnes 100 tonsCapacity
Body Capacity – SAE 2:1 60.1 m3 78.6 yd3
• Refer to the Caterpillar ® 10/10/20 Payload Guidelines.
Weights – Approximate
Target Gross Machine 163 360 kg 360,143 lbOperating Weight
777DOff-Highway Truck
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777D Off-Highway TruckEngineered for performance, designed for comfort, built to last.
Top Performance.Developed specifically for mining, quarryingand construction applications, the 777Dkeeps material moving at high volume tolower your cost-per ton.
Reliable, Durable Operation.Rugged construction and easy maintenanceprocedures ensure long life with lowoperating costs.
Matched Systems
For full truck payloads with minimumloading time, an efficient loading/haulingsystem starts with a perfect match.Cat dealers can help build an optimumsystem solution to maximizepayloads, minimize loading timeand lower operating costs. pg. 15
Truck Body Systems
Caterpillar designed and built truckbodies ensure optimal performance andreliability in tough hauling applications.Cat dealers can help build an optimumhauling system to maximize truckpayloads and extend body and truckwear life. pg. 14
Engine/Power Train Integration
The Cat Data Link electronicallycombines engine, transmission, brakeand operational information to optimizeoverall truck performance. Storeddiagnostic data can be accessed via theElectronic Technician (ET) to improvetroubleshooting and reduce downtime.pg. 6
Power Train – Transmission
The Cat seven-speed power shifttransmission, matched with the3508B electronic unit injection engine,provides consistent power and efficiencyover a wide operating speed range forpeak power train performance. pg. 5
Power Train – Engine
The Cat® 3508B EUI engine deliversthe power and reliability necessaryto perform in the most demandingapplications. Designed for efficientoperation, the 3508B offers excellentfuel efficiency, lower emissions,reduced engine noise and loweroperating costs. pg. 4
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Customer Support
Caterpillar dealers provide unmatchedproduct support, anywhere in the world.With industry-best parts availability anda wide range of maintenance and serviceoptions, Cat dealers have what it takesto keep your hauling machinesproductive. pg. 17
Serviceability
The 777D is designed for quick andeasy servicing. Simplified service andmaintenance features reduce downtime,allowing the machine to spend less timebeing serviced and more time on thehaul roads. pg. 16
Operator’s Station
The ergonomic cab is designed foroperator comfort and ease of operation.Controls and gauges are positionedwithin easy reach for optimum efficiencyand total machine control. An advancedmonitoring system keeps the 777Drunning at peak productivity. pg. 12
Structures
Caterpillar® truck frames are built toresist twisting in the most severe, highimpact applications. Mild steel providesflexibility, durability and resistance toimpact loads. Castings and forgings inhigh stress areas provide exceptionalstrength and durability for long life.pg. 10
Brake System
Cat rear oil-cooled, multiple disc brakesoffer exceptional, fade-resistant brakingand retarding for maximum performanceand productivity in all haul roadconditions. Optional AutomaticRetarder Control and Traction ControlSystems provide optimum brakingefficiency. pg. 8
Engine. The Cat 3508B EUI twinturbocharged and aftercooled dieselengine delivers high power andreliability in the world’s most demandingapplications. The 3508B is an eight-cylinder, four-stroke design that useslong, effective power strokes for morecomplete fuel combustion and optimumefficiency.
Fuel Efficiency. The 3508B EUI hastwo percent improved specific fuelconsumption over the former3508 EUI engine.
EPA Compliant. The 3508B enginemeets the U.S. Environmental ProtectionAgency Tier I emissions standards.
Starting System. Features a direct-electric,24-volt starting system with a 100-ampalternator and four 190-amp-hour, lowmaintenance, high output, 12-voltbatteries for dependable starting.
Altitude Compensation. Designed formaximum operating efficiencies ataltitudes under 2228 m (7,500 ft).
High Torque Rise. The 23 percenttorque rise provides unequalled luggingforce during acceleration, on steepgrades and in rough underfoot conditions.Torque rise effectively matchestransmission shift points for maximumefficiency and fast cycle times.
Enhanced Life. High displacement, lowrpm rating and conservative horsepowerratings mean more time on the haulroads and less time in the shop.
Two-Piece Piston Design. Two-piecearticulated pistons with a deep bowl,low volume crevice design enhancescombustion efficiency, improves fuelefficiency and lowers emissions.
Electronic Unit Injection (EUI).The electronically controlled unitinjection fuel system senses operatingconditions and regulates fuel deliveryfor optimum fuel efficiency. The provenhigh-pressure fuel system providesimproved response times and moreefficient fuel burn with lower emissionsand less smoke.
Electronic Control Module (ECM).ECM utilizes advanced enginemanagement software to monitor,control and protect the engine utilizingself-diagnosing electronic sensors.The computerized system sensesoperating conditions and powerrequirements and adjusts engine forpeak performance and most efficientoperation and at all times.
Separate Circuit Aftercooler. Allowsthe aftercooler circuit to operate coolerthan jacket water temperature for adenser air charge and greater combustion.
Engine Protection. Computerizedsystem electronically protects the engineduring cold starts, high altitude operation,air filter plugging, and high exhausttemperature.
Exhaust Diverter (optional). Uniquemuffler/exhaust design transfers heatto the truck body to keep materials fromsticking in cold climates. When in thelowered position, the diverter routes theexhaust through the body; when raised,exhaust is diverted through the muffler.
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Power Train – EngineThe Cat 3508B engine is built for power, reliability and efficiency for superior performancein the toughest applications.
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1 Electronic Unit Injection2 Two-Piece Pistons3 Separate Circuit
Aftercooler4 Valve Rotators5 Oil Cooler6 Self-Aligning
Roller Followers7 Steel-Backed Copper
Bonded Bearings
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1) Transmission. The Cat seven-speedplanetary power shift transmission ismatched with the direct-injection 3508Bdiesel engine to deliver constant powerover a wide range of operating speeds.
Robust Design. Designed for the higherhorsepower of the 3508B engine, theproven planetary power shift transmissionis built tough for long life betweenoverhauls.
Long Life. A dedicated oil tank andcircuit provides cooler, cleaner oil formaximum performance and longercomponent life.
Transmission Chassis Control (TCC).TCC uses electronically transferredengine rpm data to execute shifts atpreset points for optimum performance,efficiency and clutch life.
2) Lock-Up Torque Converter. Combinesmaximum rimpull and the cushionedshifting of torque converter drive withthe efficiency and performance ofdirect drive. Engages at approximately6.4 km/h (4 mph), delivering morepower to the wheels.
Lock-Up Clutch. Quickly releases andre-engages to reduce power train torqueloads for smoother shifting, long lifeand a more comfortable ride.
Smooth Shifting. Individual clutchmodulation provides smooth clutchengagements to optimize performanceand extend clutch life.
3) Final Drives. Cat final drives work asa system with the planetary power shifttransmission to deliver maximum powerto the ground. Built to withstand theforces of high torque and impact loads,double reduction final drives providehigh torque multiplication (19.16:1)to further reduce drive train stress.
Axles. Full floating axles are shot peenedto relieve internal stresses and increasedurability. Rolled splines also provideincreased service life.
Wheels and Rims. Cast rear wheels andCat center-mount rims are mountedusing studs and nuts to minimizemaintenance and maximize durability.
Steering System. Hydraulic steeringcontrol system is designed forexceptional smoothness and precisecontrol. A separate circuit preventscross contamination for long life.
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Power Train – TransmissionCat power train delivers more power to the ground for greater productivity and loweroperating costs.
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Cat Data Link. Electronically integratesmachine computer systems to optimizeoverall power train performance,increase reliability and componentlife and reduce operating costs.
Economy Mode. Using the ElectronicTechnician (Cat ET) service tool,the mechanic can reduce the enginesetting to 920 gross horsepower tomatch loader/crusher availability andconserve fuel.
Transmission Chassis Control (TCC).TCC uses electronically transferredengine rpm data to execute shifts atpreset points for optimum performanceefficiency and clutch life.
The transmission chassis controllerprovides integrated functionality,to the following electronic controls:
• Controlled Throttle Shifting. Regulatesengine rpm during shifting to reducepower train stress and clutch wearby controlling engine speed, torqueconverter lock-up and transmissionclutch engagement for smoother shiftsand longer component life.
• Directional Shift Management.Regulates engine speed during directionalshifts to prevent damage caused by highspeed directional changes.
• Neutral Coast Inhibitor. Preventstransmission from shifting to neutralat speeds above 6.5 km/h (4 mph) toprotect the transmission from operatingwith insufficient lubrication.
• Body-up Shift Limiter. Prevents thetransmission from shifting above apre-programmed gear without thebody fully lowered.
• Body-up Reverse Neutralizer.Automatically shifts the transmissionto neutral if the hoist lever is activatedwhile transmission is shifted in reverse.
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Electronically combines critical power train components to work more intelligentlyto optimize overall truck performance.
Engine/Power Train Integration
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1 Electronic Technician 2 CAT Data Link 3 Sensors 4 Engine Control Module (ECM) 5 Transmission Chassis Control (TCC) 6 Automatic Retarder Control (ARC) Traction Control System (TCS) Integrated Brake Control (IBC) 7 Electronic Monitoring System (EMS III) Display 8 Transmission 9 Oil-Cooled Rear Brakes10 Oil-Cooled Front Brakes (if equipped)
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• Overspeed Protection. The transmissioncontrol electronically senses engineconditions and automatically up-shiftsone gear to prevent overspeeding.If overspeeding occurs in top gear,the lock-up clutch is disengaged.
• Programmable Top Gear.Transmission top gear maximum can beset using the Cat ET service tool to helpthe operator maintain speed limits.
• Downshift Inhibitor. Prevents engineoverspeeding by keeping the transmissionfrom downshifting until engine speedreaches the downshift point.
• Economy Shift Mode. Modifies enginemaps, resulting in greater fuel economy.
• Reverse Shift Inhibitor. Protects theengine from abrupt directional changesby slowing down the engine beforeshifting the transmission into reverse.
Electronic Technician (ET). Cat ETservice tool provides service technicianswith easy access to stored diagnosticdata through the Cat Data Link tosimplify problem diagnosis and increasemachine availability.
• Cat ET displays the status of allengine parameters, including throttleposition, timing and fuel flow.
• Cat ET replaces 13 mechanical toolsto perform functions like cylindercutout checks, injector solenoid testsand timing calibration.
Diagnostic Capability. Critical datafrom the electronic engine andtransmission controls, includingtransmission shifting, engine speedand fuel consumption, provides servicetechnicians with enhanced diagnosticcapability to reduce downtime andoperating costs.
Electronic Monitoring System (EMS III).EMS III allows the operator to viewrequested information and utilizes athree-category warning system to alertthe operator of abnormal machineconditions. Data can be downloaded viathe Electronic Technician (ET) servicetool for quick diagnosis and repair.
Optional Attachments. Caterpillar offersoptional braking controls that areelectronically integrated with the CatData Link to enhance retarding, tractionand braking performance:
• Automatic Retarder Control (ARC).Optional ARC electronically controlsretarding on grade to maintain optimumengine rpm and oil cooling.
• Traction Control System (TCS).Optional TCS electronically monitorsand controls rear wheel slippage forgreater traction in poor underfootconditions.
• Integrated Braking Control (IBC).Optional IBC integrates AutomaticRetarder Control and Traction Controlinto one system for optimum performanceand efficiency.
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Integrated Braking System. The Catoil-cooled braking system deliversreliable performance and control inthe most extreme haul road conditions.The integrated system combines theservice, secondary, parking brake andretarding functions in the same robustsystem for optimum braking efficiency.
Rear Oil-Cooled Multiple Disc Brakes.Caterpillar rear-wheel, forced oil-cooled, multiple disc service brakesare continuously cooled by water-to-oilheat exchangers for exceptional, non-fade braking and retarding performance.
Brake Design. Cat oil-cooled discbrakes are designed with large discsand plates for reliable, adjustment-freeoperation and performance. Brakes arecompletely enclosed and sealed toprevent contamination and reducemaintenance.
Long Life. An oil film prevents directcontact between the discs. This designabsorbs the braking forces by shearingthe oil molecules and carrying heataway to extend brake life.
Dry Front Caliper Disc Brakes.Disc brakes fitted on front wheelsas standard fitment.
Pistons. The Caterpillar two-pistondesign combines the service, secondary,parking brake and retarding functionsin the same system. The primary pistonhydraulically actuates both serviceand retarding functions. The secondarypiston is spring-applied and held inthe disengaged position by hydraulicpressure. If hydraulic system pressuredrops below a specified level, thespring-applied secondary pistonautomatically applies the brakes.
Parking Brake. Oil-cooled, spring-applied, hydraulically released parkingbrake is applied to rear wheels forsuperior parking capability on allgrades up to 15 percent.
Automatic Retarder Control (ARC)(optional). ARC electronically controlsbraking on grade to maintain engine atapproximately 1,900 rpm (adjustablefrom 1,850-1,950 rpm in incrementsof 10). ARC is deactivated when theoperator applies the brakes or throttle.
ARC Benefits.
• Engine Overspeed Protection.Automatically activates ARC whenengine speed exceeds factory presetlevels, regardless of operator inputs,to avoid potentially damaging engineoverspeeds.
• Ease of Operation. ARC increasesoperating ease, resulting in greateroperator confidence with less fatigue.
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Reliable braking with superior control gives the operator the confidence to focuson productivity.
Brake System
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1 Parking/Secondary Piston 2 Service/Retarding Piston 3 Friction Discs 4 Steel Plates 5 Actuating Springs 6 Cooling Oil In 7 Cooling Oil Out
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• Faster Speeds. ARC allows theoperator to maintain optimum enginespeeds for faster downhill hauls andgreater productivity.
• Superior Control. Automatic brakemodulation offers a smoother ride andbetter control in slippery conditions,allowing the operating to concentrateon driving.
• Fuel Efficiency. During retardingapplications the engine ECM doesnot inject fuel into the cylinders foradditional fuel economy.
Four Corner Retarding. If equipped withfront oil cooled disc brake, four cornerretarding with 60/40 percent split(rear/front) in braking effort providessuperior control in slippery conditions.Balanced front to rear brake torqueprovides exceptional braking performanceand minimizes wheel lock-up, especiallyduring retarding.
Traction Control System (TCS) (optional).TCS electronically monitors and controlsrear wheel slippage for greater tractionand enhanced truck performance inpoor underfoot conditions. If slippageexceeds a set limit, the oil-cooled discbrakes engage to slow the spinning wheel.Torque is then automatically transferredto the wheel with better traction.
• Differential Action. Normal differentialaction provides superior maneuveringand control in slippery conditions.
• System Back-Up. Should sensors fail,normal differential action is still availableto maintain steering and control.
Integrated Braking Control (IBC)(optional). IBC combines AutomaticRetarder Control (ARC) and TractionControl System (TCS) into one integratedbrake control system for optimumefficiency, performance and reliability.
Cat Data Link. All control modulescommunicate via the Cat Data Link andwork together as an integrated systemto maximize production efficiency andextend component life.
ARC Operating Efficiency Advantages
*
10Time (Seconds)
20 30 40 50 60
Automatic Retarder Control(Maintains Engine rpm between 2160-2300)
Manual Retarder Control(Wide Variation in Engine rpm)
* Optimum Engine rpm
Engi
ne S
peed
(rpm
)
700
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TCSARC 1 Service Brake Sensor2 Engine Sensor3 ARC4 ARC Switch5 Brakes6 Service Brakes7 Axle Speed Sensor8 TCS
Box-Section Design. The 777D frameuses a box-section design, incorporatingtwo forgings and 22 castings in highstress areas with deep penetrating andcontinuous wrap-around welds to resistdamage from twisting loads withoutadding extra weight.
Steel Structures. Mild steel usedthroughout frame provides flexibility,durability and resistance to impactloads, even in cold climates, and allowsfor easy field repairs.
Castings. Castings have large radii withinternal reinforcing ribs to dissipatestress in areas of high stress concentration.Castings move welds to lower stressareas for greater frame life.
Serviceability. The open box-sectionframe design allows easy access topower train components, reducingoverall removal and installation time,and lowering overall repair costs.The raised and pinned body allowsexcellent access to the transmission.
Integral Four-Post ROPS Cab.Resiliently mounted to the main frameto reduce vibration and sound, theintegral ROPS structure is designedas an extension of the truck frame.The ROPS/FOPS structure provides“five-sided protection” for the operator.
Steering and Suspension System.Cat integrated steering and suspensionsystem is designed for precise steering,excellent maneuverability with minimaltire wear and superior ride control tooptimize operator comfort all shift long.
Steering System. A twin double-actingcylinder steering system is designed todeliver precise control under all loadingand underfoot conditions. The steeringsystem is separate from the mainhydraulic system to prevent cross-contamination and overheating fromother sources.
Supplemental Steering. Main hydraulicsteering system is backed by a batterypowered supplemental steering systemwhich uses pressure accumulators andallows up to three 90 degree turnsin case of engine failure. Systemautomatically engages when needed.
Front Spindles and Wheels. Rigidlymounted to the cylinder rods for reliableoperation and long life.
Maximum Tire Life. The steering systemis designed to maintain zero toe-in/toe-out when tie-rods and front suspensioncylinders are properly adjusted tominimize tire scuffing and maximizetire life.
Suspension System. Designed to dissipatehaul road and loading impacts for longerframe life and a more comfortable ride.
Cylinders. Four independent self-contained, nitrogen/oil pneumatic,variable-rebound suspension cylindersare designed to absorb shocks in themost severe applications.
Durable Design. Rugged cylindersutilize large diameter bore and lowpressure nitrogen/oil design for longlife with minimal maintenance.
• Front. Front cylinders with presetcaster and camber are mounted to theframe and serve as steering kingpinsfor a tight turning radius with excellentmaneuverability and low maintenance.
• Rear. Rear cylinders allow axleoscillation and absorb bending andtwisting stresses caused by uneven andrough haul roads rather than transmittingthem to the main frame.
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Rugged Cat structures are the backbone of the 777D off-highway truck’s durability.
Structures
Ride Control. Built-in rebound controland strategically located cab relative tothe front axle minimizes the effect ofpitch and bounce, resulting in a morecomfortable ride, higher productivityand less fatigue.
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1 Nitrogen2 Oil3 Rebound
Chamber4 Cylinder
Housing5 Piston
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Ergonomic Layout. The 777D operatorstation is ergonomically designed fortotal machine control in a comfortableand productive environment. All controls,levers switches and gauges are positionedto maximize productivity and minimizeoperator fatigue.
1) Dash. Wrap-around dash puts allcontrols within each reach of the operator.Backlit displays enhance visibility.
2) Air Suspension Seat. Ergonomicallydesigned, fully adjustable Cat ComfortAir Suspension Seat with adjustablearmrests provides optimal drivingcomfort. A wide, retractable seat beltprovides a secure, comfortable restraint.
3) Steering Column. Sport wheel withtilt and telescopic steering providesa comfortable driving position andgreater control.
4) Transmission Console. Ergonomicgear shift lever with backlit gearindicators optimize efficiency.
5) Viewing Area. Designed for excellentall-around visibility and clear sight linesto the haul road, the large viewing areaenables the operator to maneuver withconfidence for greater productivity.
6) ROPS/FOPS Cab. Integral, sound-suppressed cab is resiliently mountedto the mainframe to isolate the operatorfrom sound and vibration for a quiet,secure and comfortable ride.
7) Operator Controls. Easy to reachturn signal, high beam, windshieldwiper/washer, and retarder controlsare designed for optimum efficiencyand comfort.
8) Storage Compartment. Largecompartment located under the trainerseat provides an uncluttered workingenvironment.
9) Trainer Seat. Full-size, fully paddedtrainer seat features a backrest, widehip and shoulder room, and seat beltfor secure travel.
10) Monitoring System. ElectronicMonitoring System (EMS III) featureseasy-to-read displays for precisemachine status information. Data canbe downloaded via the ElectronicTechnician (Cat ET) service tool forquick diagnosis and repair.
• Gauge Cluster maintains a constantdisplay of vital machine functions,including: coolant temperature, oiltemperature, brake air pressure, andfuel level.
• Speedometer/Tachometer Modulemonitors three systems: enginespeed, ground speed and actual gear.
• Message Center displays messagesrequested by operator and advisesoperator of abnormal machineconditions.
11) Heating/Air Conditioning.Electronically controlled four-speedfan and nine vents deliver temperature-controlled air circulation for acomfortable working environmentin any climate. (optional)
12) Foot Pedals. Ergonomically designedfor comfort. Secondary brake pedal isconveniently located on the floor foreasy operator control.
13) Operator Window. Powered operatorwindow offers simple operation and anunobstructed view.
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Ergonomically designed for operator comfort, superior control and high productivity.
Operator’s Station
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14) Hoist Levers. Four-positionelectronic hoist system with fingertipcontrol provides low impact body-downsnubbing. Mounted next to theoperator’s seat for ease of operation.
15) Truck Production ManagementSystem (TPMS) (optional). TPMSprovides valuable payload and cycletime data to improve productivity.
• Utilizes strut pressure sensorsand on-board microprocessorto determine payload weight.
• Delivers consistent, accuratepayloads and improves efficiencyby minimizing overloading andunderloading.
• External lights signal loading tooloperator when payload is reached.
• On-board computer stores up to1,400 cycles for analysis of payloadweight, cycle times, distances, andactual cycle dates and times.
• System is accurate within ±5%under normal loading conditionsover a normal shift.
Radio Ready. Cab is prewired withpower converter, speakers, wiringharness, antenna and provision foradd-on communication systems.
Product Link Ready. Optional ProductLink system provides a two-waycommunication flow of vital machinedata and location information betweenthe dealer and the customer. ProductLink provides updates on service meterhours, machine condition, machinelocation as well as integratedmapping/route planning.
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Payload Weight Distribution
Payload Weight (Tons)
Perc
enta
ge o
f Tot
al L
oads
Recommended Payload Range
Inefficient Payload Ranges
With Production Management
Without Production Management
Body/Chassis Integration. Caterpillartruck bodies are designed and matchedwith the integrated chassis system foroptimum structural reliability, durabilityand long life.
Electronic Hoist Control. Provides theoperator with better control of the loadwhen dumping, including over-centerload control and modulated controlthroughout the operating range.The automatic body snubbing featurereduces impact on the frame, hoistcylinders and operator.
Fast Hoist Cycle Times. Two-stage hoistcylinders provide fast dump cycle timesof 15 seconds for raise and 13 secondsfor lower.
Body Design. Cat truck bodies aredesigned for optimal strength, capacityand durability. Wear surfaces areequipped to handle even the toughestimpact and abrasion over the long haulwithout diminishing capacity.
• Five-Sided Beams join the sidewalland floor junctions for increasedbody rigidity and strength.
• Wide Ribs in body floor provideincreased durability and impactsupport.
• Full-Length Stringers create strengthand rigidity throughout the bed.
• Box Section Beams offer increaseddurability in the floor, sidewall, toprail, corner, and cab canopy areas.
• Wide Body Design provides completecoverage of tires, eliminating theneed for rock deflectors.
Dual-Slope Body. The advanced dual-slope body design with V-shaped floorincreases load retention, maintains alow center of gravity, reduces shockloading, and maintains optimum loaddistribution on steep inclines and inchallenging haul road conditions.
• Reinforced, rolled steel top railincreases body strength and protectsthe body from damage caused bythe loading tool or falling material
• 8 degree “V” reduces shock loadingand centers the load.
• 10 degree forward body slope and18 degree ducktail slope helps retainloads on steep grades.
• Maintains a load height of 4380 mm(14 ft 3 in) for faster, more confidentloading.
• 60.1 m3 (78.6 yd3) capacity allowsoperators to achieve rated payloadin 2,900 lb/BCY material.
Body Liners. Liner options are availableto save weight and help extend the bodysystem’s life. Wear surfaces and linersare equipped to handle tough impact loadswhile resisting abrasion. Wear platesdeliver long life in high wear areas.
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Cat designed and built for rugged performance and reliability in the toughest haulingapplications.
Truck Body Systems
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Efficient Combination. The 777D isdesigned to deliver full payloads andfast cycle times. When properly matched,Cat trucks and loading tools create anefficient combination to maximizevolume of material moved at thelowest operating cost.
Machine Configuration Options.Choose from various truck configurationoptions to match specific site andhauling conditions.
Tire Options. Choose from a range oftire options to match specific underfootconditions, haul road conditions andhauling distances to maximizeperformance and extend tire life.
Systems Approach. The Caterpillarsystems approach means increasedefficiencies through common design.Cat haul trucks, loaders and excavatorsuse common engines, parts and operatorenvironments which add up to moreuptime, greater productivity and lowermaintenance costs.
Loader Match. Designed to work as anoptimum pass/match system, the 777Dis best sized to match the followingCaterpillar loading tools:
Wheel Loaders
• 990 II – 6 pass/match
• 992G – 4 pass/match
Matched SystemsAn efficient loading/hauling system starts with a perfect match.
Servicing Ease. Easy access to dailyservice points simplifies servicingand reduces time spent on regularmaintenance procedures. Enhancedserviceability and extended serviceintervals are designed to increasemachine availability and productivity.
Maintenance Platform. Provides accessto engine, air filters, steering hydraulictank and battery compartment.
In-Frame Access. Permits easy accessto major components for easy servicingand removal.
Ground-Level Access. Allows convenientservicing to tanks, filters, drains, batterydisconnect and engine shutdown.
Fast Fill Service Center (optional).Wiggins fast fill service center featureshigh speed fuel and oil exchange.
Scheduled Oil Sampling. S•O•SSM
sampling valves speed sampling andanalysis reliability.
Pressure Test Points. Disconnect valvesare conveniently located throughoutthe hydraulic systems for easypressure testing.
Air Filters. Radial seal air filters areeasy to change, reducing time requiredfor air filter maintenance.
Sealed Electrical Connectors. Electricalconnectors are sealed to lock out dustand moisture. Harnesses are braided forprotection. Wires are color coded foreasy diagnosis and repair.
Spin-on Filters. Spin-on filters for fueland oil systems reduce changing timeand help assure clean, tight seals.
On-Board Diagnostic Systems. EMS IIIcontinuously checks all critical machinefunctions and components, and helpslocate faults quickly for faster repair.Electronic control system enables quickdiagnosis of engine conditions andeffective maintenance and repairsutilizing the Electronic Technician (ET)service tool.
ServiceabilityLess time spent on maintenance means more more time on the haul roads.
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Machine Selection. Make detailedcomparisons of the machines underconsideration before purchase.Cat dealers can estimate componentlife, preventive maintenance cost,and the true cost of lost production.
Purchase. Look past initial price.Consider the financing options available,as well as day-to-day operating costs.This is also the time to look at dealerservices that can be included in the costof the machine to lower equipmentowning and operating costs over thelong run.
Financing. Your dealer is an expert atarranging affordable financing optionsfor all Caterpillar products.
Product Support. You will find nearlyall parts at your dealer parts counter.Cat dealers use a worldwide computernetwork to locate in-stock parts tominimize machine downtime. Savemoney with Cat Reman parts. Receivethe same warranty and reliability as newproducts at a savings of 40% to 70%.
Literature Support. Operation andmaintenance manuals are easy to use,helping you get the full value of yourequipment investment.
Customer Support Agreements.Cat dealers offer a variety of productsupport agreements, and work withcustomers to develop a plan that meetsspecific needs. Plans can cover theentire machine, including attachments,to help protect your investments.
Operation. Improving operatingtechniques can boost your profits.Your Cat dealer has training videotapes,literature and other ideas to help youincrease productivity.
Replacement. Repair, rebuild orreplace? Your Cat dealer can help youevaluate the cost involved so you canmake the right choice.
www.cat.com. For more completeinformation on Cat products, dealerservices, and industry solutions, visit uson the web at www.cat.com.
Customer SupportCaterpillar dealers have what it takes to keep haul trucks productive.
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Final Drives
Differential Ratio 2.74:1Planetary Ratio 7.00:1Total Reduction Ratio 19.16:1
• Planetary, full-floating.
Brakes
Brake Surface – Front 2787 cm2 432 in2
Brake Surface – Rear 102 116 cm2 15,828 in2
• Meets ISO 3450:1996 standards up to 163 293 kg (360,000 lb)gross operating weight.
Body Hoists
Pump Flow – High Idle 498 L/min 131.5 gal/minRelief Valve Setting – Raise 18 962 kPa 2,750 psiRelief Valve Setting – Lower 18 950 kPa 3,450 psiBody Raise Time – High Idle 15 SecondsBody Lower Time – Float 13 SecondsBody Power Down – High Idle 13 Seconds
Capacity – Dual Slope – 100% fill factor
Struck 42.1 m3 55 yd3
Heaped 2:1 (SAE) 60.1 m3 78.6 yd3
Weight Distributions – Approximate
Front Axle – Empty 47%Front Axle – Loaded 33%Rear Axle – Empty 53%Rear Axle – Loaded 67%
Suspension
Effective Cylinder Stroke – Front 318 mm 12.5 inEffective Cylinder Stroke – Rear 165 mm 6.5 inRear Axle Oscillation 5.4º
Engine
Engine Model Cat® 3508B EUIGross Power – SAE J1995 746 kW 1,000 hpNet Power – SAE J1349 699 kW 938 hpNet Power – Cat 699 kW 938 hpFlywheel Power 699 kW 938 hpNet Power – ISO 9249 699 kW 938 hpNet Power – 80/1269/EEC 699 kW 938 hpPeak Torque 4713 N·m 3,476 lb ftTorque Rise 23%Bore 170 mm 6.7 inStroke 190 mm 7.5 inDisplacement 34.5 L 2,105 in3
• Net power advertised is the power available at rated speedof 1750 rpm, measured at the flywheel when the engine isequipped with fan, air cleaner, muffler and alternator.
• Ratings based on standard air conditions of 25° C (77° F) and99 kPa (29.32 Hg) dry barometer. Power based on fuel havingAPI gravity of 35 at 16° C (60° F) and an LHV of 42 780 kJ/kg(18,390 BTU/lb) when engine used at 30° C (86° F).
• No engine derating required up to 2288 m (7,500 ft) altitude.
• Meets U.S. Environmental Protection Agency Tier 1emissions standards.
Weights – Approximate
Target Gross Machine 163 360 kg 360,143 lbOperating WeightOperating Weight – empty 64 670 kg 142,573 lb
Operating Specifications
Nominal Payload Capacity 90.4 tonnes 100 tonsBody Capacity – Struck 42.1 m3 55.06 yd3
Body Capacity – SAE 2:1 60.1 m3 78.6 yd3
• Refer to the Caterpillar 10/10/20 Payload Guidelines.
Transmission
Forward 1 10.5 km/h 6.5 mphForward 2 14.3 km/h 8.9 mphForward 3 19.3 km/h 12 mphForward 4 26 km/h 16.2 mphForward 5 34.9 km/h 21.9 mphForward 6 46.6 km/h 29.4 mphForward 7 60.4 km/h 39.9 mphReverse 11.9 km/h 7.4 mph
• Maximum travel speeds with standard 27.00-R49 tires.
19777D Off-Highway Truck specifications
Sound
Sound Standards ANSI/SAE J1166 MAY90,SAE J88 JUN96
• The operator sound exposure Leq (equivalent soundpressure level) measured according to work cycleprocedures specified in ANSI/SAE J1166 MAY90 is 78 dB(A)for cab offered by Caterpillar, when properly installed andmaintained and tested with doors and windows closed.
• The exterior sound pressure level for the standard machinemeasured at a distance of 15 m (49 ft) according to the testprocedures specified in SAE J88 JUN86, mid-gear movingoperation is 90 dB(A).
• Hearing protection may be needed when operating withan open operator station and cab (when not properlymaintained or doors/windows open) for extended periodsor in a noisy environment.
Steering
Steering Standards SAE J1511 OCT90,ISO 5010:1992 (E)
• Turning diameter on front wheel track with standard tires:25.3 m (83 ft).
• Machine clearance turning circle: 28.4 m (93 ft 2 in).
• Steering angle, left or right: 30.5 degrees.
• Separate hydraulic system prevents cross contamination.
Approximate Weights – Dual Slope
Empty vehicle 64 670 kg 142,573 lbChassis 46 600 kg 107,144 lbBody 16 070 kg 35,428 lb
Service Refill Capacities
Fuel Tank 1137 L 300 galCooling System 268 L 71 galCrankcase 91 L 24 galDifferentials and Final Drives 306 L 81 galSteering Tank 40 L 11 galTorque Converter/Brake/ 250 L 66 galHoist Hydraulic TankTorque Converter/ 95 L 25 galTransmission Tank
Tires
Standard Tire 27.00-R49 (E4) Tire
• Productive capabilities of the 777D truck are such that,under certain job conditions, TKPH (TMPH) capabilities ofstandard or optional tires could be exceeded and, therefore,limit production.
• Caterpillar recommends the customer evaluate all jobconditions and consult the tire manufacturer for propertire selection.
ROPS
ROPS/FOPS Standards SAE J1040 MAY94,ISO 3471:1997
• ROPS (Rollover Protective Structure) for cab offered byCaterpillar meets SAE J1040 MAY94 and ISO 3471:1997Level II ROPS criteria.
20 777D Off-Highway Truck specifications
DimensionsAll dimensions are approximate. (Shown with dual slope body)
Dual Slope1 Height to Top of ROPS – Full 4472 mm 14 ft 8 in1 Height to Top of ROPS – Empty 4567 mm 15 ft2 Overall Body Length 9525 mm 31 ft 3 in3 Inside Body Length 7234 mm 23 ft 9 in4 Overall Length 9780 mm 32 ft 1 in5 Wheelbase 4570 mm 15 ft6 Rear Axle to Tail 3020 mm 9 ft 11 in7 Dump Clearance – Empty 1164 mm 3 ft 10 in7 Dump Clearance – Loaded 1062 mm 3 ft 6 in8 Loading Height – Empty 4380 mm 14 ft 4 in9 Inside Body Depth – Max 1898 mm 6 ft 3 in10 Overall Height – Body Raised 10 059 mm 33 ft
Dual Slope11 Operating Width 6105 mm 20 ft12 Centerline Front Tire Width 4173 mm 13 ft 8 in13 Overall Front Tire Width 4961 mm 16 ft 3 in14 Engine Guard Clearance – Empty 700 mm 2 ft 4 in15 Overall Canopy Width 6048 mm 19 ft 10 in16 Outside Body Width 5524 mm 18 ft 2 in17 Inside Body Width 5200 mm 17 ft 1 in18 Front Canopy Height – Empty 5147 mm 16 ft 10 in18 Front Canopy Height – Loaded 5045 mm 16 ft 6 in19 Rear Axle Clearance – Empty 750 mm 2 ft 6 in20 Centerline Rear Dual Tire Width 3576 mm 11 ft 9 in21 Overall Rear Dual Tire Width 5262 mm 17 ft 3 in
19
14
49.4
9
7
3
18
1
2
4
5 6
8
18°
10
11
12
13
15
16
17
20
21
21777D Off-Highway Truck specifications
To determine gradeability performance: Read from grossweight down to the percent of total resistance. Total resistanceequals actual percent grade plus 1% for each 10 kg/t (20 lb/ton)of rolling resistance. From this weight-resistance point, read
horizontally to the curve with the highest obtainable gear, thendown to maximum speed. Usable rimpull will depend upontraction available and weight on drive wheels.
Gradeability/Speed/Rimpull
20
120100
70
50
30
20
10
5
3
2
1
0.50
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 km/h
mph
lb x 1000kg x 1000
lb x 1000
kg x 1000
5 10 15 20 25 30 35 40 45 50
0.30
0.50
1
2
3
5
10
20
30
40
50
50 100 150 200 250 300 400 500
30 40 50 60 80 100 150 200
Gross Weight
SPEED
RIM
PULL
EFFE
CTIV
E G
RAD
E (F
avor
able
)
1st Gear E L
1st Gear
2nd Gear
3rd Gear4th Gear
5th Gear
6th Gear
7th Gear
30% 20%
15%12%10%8%
6%
4%
2%
Torque Converter DriveDirect Drive
Typical Field Empty Weight
163 360 kg (360,143 lb) Load
22 777D Off-Highway Truck specifications
0 50 100 150 200 250 300 350 400 450 lb x 1000
0 30 60 90 120 150 180 210 kg x 1000
0 10 20 30 40 50 60 70 80 km/h
0 5 10 15 20 25 30 35 40 45 50 mph
SPEEDGrade Distance — 450 m (1500 ft.)
EFFE
CTIV
E G
RAD
E (F
avor
able
)
Gross Weight
10%
5%
15%
20%
25%30%
4th Gear
3rd Gear
2nd Gear
1st Gear
6th Gear
5th Gear
7th Gear
0 50 100 150 200 250 300 350 400 450 lb x 1000
0 30 60 90 120 150 180 210 kg x 1000
0 10 20 30 40 50 60 70 80 km/h
0 5 10 15 20 25 30 35 40 45 50 mph
SPEEDGrade Distance — 600 m (2000 ft.)
EFFE
CTIV
E G
RAD
E (F
avor
able
)
Gross Weight
10%
5%
15%
20%
25%30%
5th Gear
4th Gear
3rd Gear
2nd Gear
1st Gear
6th Gear7th Gear
Retarding Performance
23777D Off-Highway Truck specifications
0 50 100 150 200 250 300 350 400 450 lb x 1000
0 30 60 90 120 150 180 210 kg x 1000
0 10 20 30 40 50 60 70 80 km/h
0 5 10 15 20 25 30 35 40 45 50 mph
SPEEDGrade Distance — 900 m (3000 ft.)
EFFE
CTIV
E G
RAD
E (F
avor
able
)
Gross Weight
10%
5%
15%
20%
25%30%
5th Gear
4th Gear
3rd Gear
2nd Gear
1st Gear
6th Gear 7th Gear
0 50 100 150 200 300250 350 400 450 lb x 1000
0 30 60 90 120 150 180 210 kg x 1000
0 10 20 30 40 50 60 70 80 km/h
0 5 10 15 20 25 30 35 40 45 50 mph
SPEEDGrade Distance — 1500 m (5000 ft.)
EFFE
CTIV
E G
RAD
E (F
avor
able
)Gross Weight
10%
5%
15%
20%
25%30%
5th Gear
1st Gear
7th Gear6th Gear
2nd Gear
3rd Gear
4th Gear
Retarding Performance
24 777D Off-Highway Truck specifications
To determine retarding performance: Add lengths of alldownhill segments and, using this total, refer to properretarding chart. Read from gross weight down to the percenteffective grade. Effective grade equals actual % grade minus1% for each 10 kg/t (20 lb/ton) of rolling resistance. From thisweight-effective grade point, read horizontally to the curvewith the highest obtainable gear, then down to maximumdescent speed brakes can properly handle without exceeding
cooling capacity. The following charts are based on theseconditions: 32° C (90° F) ambient temperature, at sea level,with 27.00-R49 tires.
NOTE: Select the proper gear to maintain engine rpm at the highestpossible level, without overspeeding the engine. If cooling oiloverheats, reduce ground speed to allow transmission to shift tothe next lower speed range.
Retarding Performance
0 50 100 150 200 300250 350 400 450 lb x 1000
0 30 60 90 120 150 180 210 kg x 1000
0 10 20 30 40 50 60 70 80 km/h
0 5 10 15 20 25 30 35 40 45 50 mph
SPEEDContinuous Grade Length
EFFE
CTIV
E G
RAD
E (F
avor
able
)
Gross Weight
10%
5%
15%
20%
25%30%
5th Gear
4th Gear
3rd Gear
2nd Gear
1st Gear
6th Gear7th Gear
Gross Machine Operating Weight163 360 kg (360,143 lb)
Typical Field Empty Weight
25777D Off-Highway Truck specifications
Standard EquipmentStandard equipment may vary. Consult your Caterpillar dealer for details.
GaugesActual Gear IndicatorAir Cleaner Service IndicatorAir PressureBody Down IndicatorBrake Oil TemperatureCoolant TemperatureEngine Overspeed IndicatorFuel LevelHour MeterLoad Counter, automaticOdometerSpeedometerTachometer
Lighting SystemAuxiliary Jump Start ReceptacleBack-up LightsDirectional Signals and Hazard Warning, LEDDome/Courtesy LightHeadlights, Halogen, with dimmerStop and Tail Lights, LED
Mirrors, right/leftReservoirs (separate)
Brake/Converter/HoistSteeringTransmission/Torque Converter
Rims, 19.5 � 49Rock EjectorsService Platform, bolt-onSupplemental Steering, automatic Tires, 27.00-R49, radialTow Hooks, frontTow Pin, rearTransmission
7-Speed Automatic Power Shift, electronic controlBody-up Shift LimiterControlled Throttle ShiftingDirectional Shift ManagementDownshift/Reverse Shift InhibitorEconomy Shift ModeEngine Overspeed ProtectionReverse Neutralizer During DumpingNeutral Coast InhibitorNeutral Start SwitchProgrammable Top Gear Selection
Vandalism Protection LocksWindshield Wipers and Washer, electric intermittent
Air Line DryerAlternator (100-amp)Alarm, Back-upBatteries, 190-amp hour, 12-volt (4)Battery Disconnect Switch, ground levelBody Mounting GroupBody Safety PinsBody Up Reverse InhibitorBraking System
Brake Disconnect Switch, frontBrake Heat ExchangerBrake Release Motor for TowingOil-Cooled Multiple Disc Brakes (rear)Parking BrakeRetarderSecondary Brake
Cab, ROPSCoat HookDiagnostic Connector Port, 24-voltElectronic Monitoring System IIIHoist Lever, finger tip-actuatedHorn, airInsulated and Sound-SuppressedPower Port, 24-voltProduct Link ReadyRadio Ready, 5-amp converter, speakers, antenna, wiringSeat, Caterpillar Comfort, full air suspensionSeat Belts, 75 mm (3 in) wide retractableSeat, PassengerSteering Wheel, tilt, padded, telescopicStorage CompartmentSun VisorTinted GlassWindow, electric (operator)
Coolant, Extended Life, –35° C (–30° F)Crankcase GuardDrive line GuardElectrical System, 24-voltEngine
Cat 3508B Electronic Unit Injection8-Cylinder DieselTurbochargedAftercooledAir Cleaner with Precleaner (2)Automatic Cold Mode Idle ControlElectric StartEngine Shutdown Switch, ground levelStarting Aid, Ether
Filters, Spin-on
26 777D Off-Highway Truck specifications
Optional EquipmentOptional equipment may vary. Consult your Caterpillar dealer for details.
Lubrication Group – AutomaticMufflerMuffler/Exhaust DiverterWiggins Service Center
Air ConditioningAutomatic Retarder Control (ARC), dryBody Tail End Liner
Dual SlopeFuel Fast Fill AdapterFuel TankIntegrated Braking Control (IBC), dry
Combines Traction Control System (TCS) and Automatic Retarder Control (ARC) into one system.
Dual Slope Dual Slope w/LinerCHASSIS kg lb kg lbEmpty Chassis Weight + 10% fuel 48 600 107,144 48 600 107,144
Fuel Correction (90% × 300 × 7.1 lb/gal) 870 1,918 870 1,918
Optional Attachments Weight Debris Allowance (4% of chassis weight) +1944 +4,286 +1944 +4,286
Total Chassis Weight 51 414 113,347 51 414 113,347
BODYBody Weight 16 070 35,428 16 070 35,428
Body Attachment Weights 5 432 11,975
Total Body Weight +16 070 +35,428 +21 502 +47,403
Total Empty Operating Weight 67 484 148,775 72 916 160,751
Target Payload +95 876 +211,368 +90 444 +199,393
Gross Machine Operating Weight 163 360 360,143 163 360 360,143
* Refer to Caterpillar’s 10/10/20 Payload Policy for Quarry and Construction Trucks.
Weight/Payload Calculation*(Example)
27777D Off-Highway Truck specifications
Notes
R
For more complete information on Cat products, dealer services, and industry solutions, visit us on the web at www.cat.com
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Printed in U.S.A.
Materials and specifications are subject to change without notice.Featured machines in photos may include additional equipment.
See your Caterpillar dealer for available options.
CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow” and thePOWER EDGE trade dress, as well as corporate and product identity used herein,
are trademarks of Caterpillar and may not be used without permission.AEHQ5855 (3-07)
777D Off-Highway Truck
